Method and system for fireplace conversion

ABSTRACT

A method and system for conversion of a fireplace to an updated or different model or configuration is provided. For example, such conversion can apply to any fireplace configuration, indoor and outdoor, commercial and residential, to provide a different fireplace appearance. A converted fireplace comprises an existing firebox, an existing exhaust system, a shell and replacement firebox, and an exhaust adapter. The firebox and exhaust system typically comprise the existing structure within a residential or commercial fireplace installation. The firebox can he of various heights, widths and depths, and yet still be converted, while the exhaust system can comprise various configurations, such as B-vent, direct vent and the like, and yet coupled to the replacement fireplace unit.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and benefit of U.S. Provisional Application No. 61/723,407, filed on Nov. 7, 2012 and entitled “METHOD AND SYSTEM FOR FIREPLACE CONVERSION.”

Technical Field

The present invention relates, generally, to fireplaces, and in particular to a method and system for conversion of fireplaces into an updated or otherwise different configuration or appearance.

BACKGROUND OF THE INVENTION

Various fireplaces for residential and commercial users have been made available to consumers over the years with increased efforts to provide for more aesthetically pleasing configurations.

Unfortunately, much like buying a new car, once a new fireplace is purchased and installed, the consumer will likely need to keep the selected fireplace design for many years before updating or changing the fireplace design or appearance. This is because removing the existing system and installing a completely new fireplace results in substantial additional expense in labor and materials, i.e., essentially a duplication in original installation investment in efforts and costs, and thus requires most consumers to continue use that original design to realize their monetary investment in the selected fireplace design before changing out to an updated design.

SUMMARY OF THE INVENTION

In accordance with various aspects of the present invention, a method and system for conversion of a fireplace to an updated or different model or configuration is provided. For example, such conversion can apply to any fireplace configuration, indoor and outdoor, commercial and residential, to provide a different fireplace appearance.

In accordance with an exemplary embodiment, a converted fireplace comprises an existing firebox, an existing exhaust system, a shell and replacement firebox, and an exhaust adapter. The firebox and exhaust system typically comprise the existing structure within a residential or commercial fireplace installation. The firebox can be of various heights, widths and depths, and yet still be converted into a variety of configurations, while the exhaust system can also comprise various configurations, such as B-vent, direct vent and the like, and yet coupled to the replacement fireplace unit. In an exemplary embodiment, the shell comprises a body, a pair of framing channels, and a pair of adjusting legs and is configured to be suitably aligned within the firebox, while the replacement firebox is configured to slide within the shell and provide the front fireplace appearance. Further, the exhaust adapter comprises a collar plate and an adapter component, and depending on the spacing, the type of fireplace type and the exhaust configuration, can possibly include one or more flex liners, and can be further configured to operatively couple the replacement firebox/shell to the existing exhaust system.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The exemplary embodiments of the present invention will be described in conjunction with the appended drawing figures in which like numerals denote like elements and:

FIG. 1 illustrates a block diagram of an exemplary system for conversion of a fireplace in accordance with an exemplary embodiment of the present invention;

FIGS. 2A-2C illustrate front, top, side and perspective views of exemplary converted fireplaces in accordance with an exemplary embodiment of the present invention;

FIG. 3 illustrates an exploded, perspective view of a shell and exhaust adapter configured within a firebox in accordance with an exemplary embodiment of the present invention;

FIGS. 4A-4D illustrate side view diagrams of exemplary fireplace inserts with B-vent exhaust configurations in accordance with an exemplary embodiment of the present invention;

FIGS. 5A-5D illustrate perspective views of exemplary fireplace inserts with B-vent exhaust configurations in accordance with an exemplary embodiment of the present invention;

FIGS. 6A-6C illustrate side view diagrams of an exemplary fireplace insert with direct vent exhaust configuration in accordance with an exemplary embodiment of the present invention;

FIGS. 7A and 7B illustrate perspective views of exemplary fireplace inserts with direct vent exhaust configurations in accordance with an exemplary embodiment of the present invention;

FIG. 8 illustrates an exploded view of a fireplace conversion including modification of the venting configuration from a B-vent to a direct vent exhaust in accordance with an exemplary embodiment of the present invention; and

FIG. 9 illustrates an exemplary method for fireplace conversion in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present invention may be described herein in terms of various materials, composites and functional components. It should be appreciated that such materials, composites and functional components may be realized by any number of characteristics and configurations. For example, while examples of the conversion system and method are discussed with respect to conventional fireplaces, any fireplace insert configuration can be utilized to provide an updated or different configuration or appearance.

As used herein, the term “flex liner” includes flex sections, flex vent liners, and flex vents. Flex liners may be made of aluminum.

In accordance with various aspects of the present invention, a method and system for conversion of a fireplace to an updated or different model or configuration is provided. For example, such conversion can apply to providing a replacement unit for any fireplace configuration, indoor and outdoor, commercial and residential, to provide a different fireplace appearance.

In accordance with an exemplary embodiment, with reference to FIG. 1, a converted fireplace system or unit 100 comprises an existing firebox 120, an existing exhaust system 140, a shell and replacement firebox 160, and an exhaust adapter 180. Firebox 120 and exhaust system 140 typically comprise the existing structure within a residential or commercial fireplace installation. Of course, either or both of firebox 120 and exhaust system 140 can be suitably replaced or modified; however, keeping the existing components and structures reduces the cost for fireplace conversion. Firebox 120 can be of various heights, widths and depths, and yet still be reconfigurable to a new or updated replacement unit to be positioned within. In some installations, various parts and components, such as the existing shell, pan, baffle or other components are removed to allow for insertion of shell/replacement firebox 160 within. Similarly, exhaust system 140 can comprise various configurations, such as B-vent exhaust configurations (for example that illustrated in FIG. 2A, wherein the intake portion of exhaust system unit pulls air from within the room), and/or direct vent exhaust configurations (for example that illustrated in FIG. 2C, wherein the exhaust is self-contained and the intake pulls air from external area of the vent cap and circulates through the unit and back through the exhaust). Reusing existing firebox 120 and exhaust system 140 provides for significant cost savings for the consumer during the conversion process, as the firebox structural supports and mounting, as well as piping supports and the like can be substantially retained.

To facilitate conversion of the fireplace appearance or design, shell and replacement firebox 160 comprise a shell body, a pair of framing channels, and a pair of adjusting legs and is configured to be suitably aligned within firebox 120, despite firebox 120 having various sizes (heights, widths and depths). For example, in accordance with an exemplary embodiment, with additional reference to FIG. 3, a shell 360 comprises a body 362, a top 364, a pair of framing channels 366 and 368, and a pair of adjusting legs 370 and 372 to facilitate alignment within firebox 120. Body 362 and top 364 are suitably selected and configured to have a width approximately the width of firebox 120, i.e., body 362 and top 364 can be positioned within firebox 120. While FIG. 3 illustrates separate components for body 362 and top 364, in other embodiments, top 364 can be integrated into body 362 to form a single structure (or at least can be attached to body 362 before positioning both components within firebox 120). Body 362 and top 364 can comprise various thicknesses and metal alloy structures conventionally used for fireplace inserts.

Framing channels 366 and 368 are suitably selected to have heights approximate that of body 362 and are configured to facilitate attachment of body 362 (and thus top 364) to firebox 120. While FIG. 3 illustrates a pair of framing channels 366 and 368, in other embodiments, additional framing channels can be positioned, e.g., along the top and/or along the bottom sides of body 362. Adjusting legs 370 and 372 are suitably located proximate the sides and bottom of body 362, and are configured to support the elevation of body 362 (and thus top 364) within firebox 120, e.g., to provide leveling legs once body 362 is mounted to existing firebox 120 via exhaust adapter 180. While FIG. 3 illustrates a pair of legs 370 and 372, in other embodiments, additional legs can be positioned, e.g., along the back and/or proximate to the other legs located along the bottom sides of body 362, or other supporting elements can be provided to facilitate support of shell body 362 to thereafter contain the replacement firebox and valve systems. During installation, the height of body 362 is first determined and set (based on coupling to exhaust adapter 180 and exhaust system 140), the adjustment legs 370 and 372 are adjusted to the existing firebox floor, and then framing channels 366 and 368 are attached to the front of body 362.

Exhaust adapter 180 is configured to facilitate operative coupling of shell/replacement firebox 160 to existing exhaust system 140. In various exemplary embodiments, exhaust adapter 180 comprises a collar plate, a flex liner and an adapter component, with different configurations of such components depending on the type of exhaust system currently used, e.g., B-vent or direct vent, or desired, as well as the spacing available from top of shell 160 to the exhaust system.

For example, with reference to an exemplary embodiment illustrated in FIG. 4A and

FIG. 5A, an exhaust adapter 480 can be configured to operatively couple a B-vent shell 460 within a firebox 420 to B-vent type of exhaust system 440 where moderate spacing is available. In this embodiment, exhaust adapter 480 comprises a collar plate 482, a flex liner 484 and an adapter component comprising a gasket 490. Collar plate 482 is configured to attach or couple to the top of shell 460 and provide an opening for venting. For example with reference to FIG. 5A, a collar plate 582 can comprise a sliding arrangement coupled to a top 564 of the shell, with the sliding arrangement designed to permit shell 562 to slide onto collar plate 582 after mounting or otherwise connecting to the existing firebox. However, collar plate 582 can suitably comprise any other configurations for providing a collar coupling to a firebox or insert.

To facilitate coupling of collar plate 482 to an existing exhaust piping 492 of exhaust 440, in this particular exemplary embodiment, flex liner 484 is configured to be suitably smaller in diameter than piping 492, e.g., a 4 inch (4″) liner and 5 inch (5″) B-vent pipe, and having a length such that flex liner 484 can be suitably inserted within piping 492. To provide a secure fitting, flex liner 484 has gasket 490 suitably configured to fit securely around flex liner 484 and having an outer diameter configured to fit securely inside of piping 492 once flex liner 484 and gasket 490 are inserted within piping 492. For example with further reference to FIG. 5A, a short flex section 584 can be suitably coupled on one end to collar plate 582 by adapting around a protruding collar component of collar plate 582, clamped or unclamped, and then coupled to a gasket rope section 590 proximate the other end to facilitate a secure coupling within the B-vent exhaust piping. While FIG. 5A illustrates a protruding collar component for coupling flex section 584 to collar plate 582, any other coupling configuration can be used, e.g., flex section 584 can be aligned within an opening of collar plate 582 and attached underneath, or integrally formed within collar plate 582. Similarly, gasket 590 can comprise various configurations and types, positioned around the outer diameter and proximate to the end of flex liner 584, or attached to the outer edges of the end of flex liner 584. As a result, a secure exhaust pathway with the needed integrity between shell 460 and existing exhaust 440 can be realized.

In accordance with other exemplary embodiments, for example, with reference to

FIG. 4B and FIG. 5B, rather than use a gasket configuration, an exhaust adapter 480 can be configured to operatively couple a B-vent shell 460 to a B-vent type of exhaust system 440 (again, where moderate spacing is available) by including collar plate 482, flex liner 484 and an adapter component comprising an adapter plate 486. Collar plate 482 is configured to attach or couple to the top of shell 460 and provide an opening for venting. For example with reference to FIG. 5B, a collar plate 582 can again comprise a sliding arrangement to fit within a top 564 of the shell, or any other suitably configurations for collar plates.

In this exemplary embodiment, to facilitate coupling of collar plate 482 to an existing exhaust piping 492 of exhaust 440, flex liner 484 is configured to be suitably smaller in diameter than piping 492, e.g., a 4″ liner and 5″ B-vent pipe, and having a length that extends approximately within the spacing between collar plate 482 and the top of firebox 420. To couple flex liner 484 to the top of firebox 420 (and thus to piping 492), rather than incorporating a gasket configuration, an adapter plate 486 can be utilized. For example with further reference to FIG. 5B, a short flex section 584 can be suitably coupled on one end to collar plate 582 and then similarly coupled, e.g., by adapting around a protruding collar component of adapter plate 586, clamped or unclamped, proximate the other end to facilitate a secure coupling to the undersurface of the top of firebox 420, and thus to the B-vent exhaust piping. As a result, a secure exhaust pathway with the needed integrity between shell 460 and existing exhaust 440 can again be realized.

In some B-vent installations, the spacing between the top of shell 460 and the top of firebox 420 is very minimal, such that no flex liner is suitably needed, or in other cases, the structural or operational integrity of existing piping 492 is in question. For example, with reference to FIG. 4C and FIG. 5C, rather than use a flex liner configuration, shell 460 can be suitably positioned within firebox 420, to provide minimal spacing. In such an embodiment, exhaust adapter 480 can be configured with just a collar plate 482 having an integrated adapter configured to attach or couple to the top of firebox 420 and provide an opening for venting. For example with reference to FIG. 5C, a collar plate 582 can again comprise a sliding arrangement to fit within a top 564 of the shell, and then to facilitate coupling of collar plate 582 to an existing exhaust piping 492 of exhaust 440, an adapter plate with a gasket can be utilized. For example with further reference to FIG. 5B, a short flex section 584 can be suitably coupled on one end to collar plate 582 and then similarly coupled, e.g., by adapting around a protruding collar component of adapter plate 586, clamped or unclamped, proximate the other end to facilitate a secure coupling to the undersurface of the top of firebox 420, and thus to the B-vent exhaust piping. In yet other installations, wherein the integrity of the existing piping 492 is in question (or the coupling thereof to firebox 420), with reference to FIG. 4D and FIG. 5D, exhaust adapter 480 can comprise collar plate 482/582 and flex liner 484/584, wherein flex liner 484/584 is configured to extend within piping 492, ultimately coupling to termination vent cap. Again, a secure exhaust pathway with the needed integrity between shell 460 and existing exhaust 440 can be realized.

As discussed, exhaust adapter 180 can be configured as well with any other venting arrangements for fireplaces. For example, with reference to an exemplary embodiment illustrated in FIG. 6A for a direct vent fireplace, an exhaust adapter 680 can be configured to operatively couple a direct vent shell 660 within a firebox 620 to a direct vent type of exhaust system 640 where moderate spacing is available (similar to the embodiments illustrated in FIG. 4B and FIG. 5B). In this embodiment, exhaust adapter 680 comprises a collar plate 682, an outer flex liner 684 and an adapter component comprising an adapter plate 686. Collar plate 682 is configured to attach or couple to the top of shell 660 and provide an opening for venting. For example, with reference to FIGS. 7A and 7B, collar plate 782G can again comprise a sliding arrangement to fit within a top of the shell with slide retainers 782D, otherwise similar to that illustrated in FIG. 5B, or any other suitable configurations for collar plates. In addition, collar plate 682/782G can have an inner exhaust collar 782, including exhaust collar mounting bracket 782A, and an outer intake collar 782C. The sliding arrangement can comprise two slides where a vent adaptor slide 782B mounts the intake collar 782C to an exhaust collar plate 782E by an exhaust collar mounting bracket 782A. The second slide comprises the collar plate 782G with a flue connector 782H.

In this exemplary embodiment, flex liner 684 is configured to be suitably smaller in diameter than outer piping 692, e.g., a 4″ liner and a 5″ or 6″ vent pipe, but could also have a diameter as substantially the same as the piping, and having a length that extends approximately within the spacing between collar plate 682 and the top of firebox 620. To couple flex liner 684 to the top of firebox 620 (and thus to piping 692), adapter plate 686 is utilized, for example similar to the configuration illustrated in FIG. 5B, a short flex section 684 can be suitably coupled on one end to collar plate 682 (for example to intake collar 782C) and then similarly coupled, e.g., by adapting around a protruding collar component of adapter plate 686.

In this embodiment for direct vent fireplace exhaust, flex liner 684 is configured with piping 692 to provide air intake, with exhaust system 640 further including another collar 694, a collar adapter 696 and a direct vent termination vent cap 698. Collar 694 can suitably comprise a custom size collar, e.g., 5″ or 6″ collar, or other similar arrangements for coupling piping to adapters and then connecting to vent caps. Collar adapter 696 can comprise a universal collar adapter, configured for coupling both an intake and exhaust piping system to a direct vent cap 698, which can comprise any direct vent termination cap configuration now known or hereinafter devised. As a result, a secure intake pathway with the needed integrity between direct vent shell 660 and direct vent cap 698 is realized.

Further, in accordance with the direct-vent embodiments, exhaust adapter 680 further includes a second flex liner 688 that is suitably coupled to collar plate 682, e.g., coupled to exhaust collar 782, and then extends through flex liner 684, adapter plate 686, piping 692, and collar 694 and terminating at collar adapter 696. Thus, a second secure pathway for exhaust is provided between shell 660 and direct vent cap 698.

In direct vent installations where the spacing between the top of shell 660 and the top of firebox 620 is very minimal, such that no flex liner is suitably needed, or in other cases, wherein the structural or operational integrity of existing piping 492 is in question, other embodiments can be implemented. For example, with reference to FIG. 6B, rather than use a flex liner configuration such as flex liner 684 illustrated in FIG. 6A, shell 660 can be suitably positioned within firebox 620, with or without use of adjustment legs 770 and 772, to provide minimal spacing. In such an embodiment, exhaust adapter 680 can be configured with a collar plate 682 having an integrated adapter or gasket configured to attach or couple to the top of firebox 620 and provide an opening for intake venting, similar to that illustrated with reference to FIG. 5C for B-vent configurations. Otherwise, flex liner 688, collar 694, collar adapter 696 and direct vent cap 698 can be similar to embodiments associated with the configurations in FIG. 6A. In yet other installations, for example with reference to FIG. 6C, wherein the integrity of the existing piping 692 is in question (or the coupling thereof to firebox 620 for to the direct vent caps), exhaust adapter 680 can again comprise both flex liner 684 (for intake venting) and flex liner 688 (for exhaust), but rather than having flex liner 684 terminate at an adapter plate (as illustrated with adapter plate 686 in FIG. 6A), flex liner 684 can continue to extend through piping 692 and collar 694, and also terminating at collar adapter 696. Thus, in this embodiment, collar adapter is configured to operatively couple both intake flex liner 684 and exhaust flex liner 688 to direct vent termination caps, resulting in integral intake and exhaust pathways between shell 660 and direct vent cap 698 even in the presence of original derogated exhaust systems 640.

While the above exemplary embodiments illustrate the conversion of older, existing B-vent fireplaces into updated or newer ones (as well as the conversion of older, existing direct vent fireplaces into updated or newer direct vent models), it should be appreciated that the B-vent fireplaces can also be suitably converted into direct vent configurations. For example, with additional reference to FIG. 8, even if firebox 120 and exhaust system 140 were originally configured for B-vent operation, the conversion of the fireplace can be provided to convert the fireplace into a direct vent fireplace configuration. In such an application, the direct vent shell, such as shell 660, is inserted into the firebox and then suitably adjusted. Depending on the height and spacing, any one of exhaust adapter configurations illustrated in FIGS. 6A, 6B or 6C can be utilized. For example, FIG. 8 illustrates an example where a flex vent liner 802 (for example, a 4″ aluminum flex vent) is coupled to a collar adapter plate 804 for coupling to the top of the firebox. In this embodiment, collar adapter plate 804 is further coupled to a B-vent 4″ solid pipe 806, having a 2½″ flex vent liner 810 within. B-vent pipe 806 can be coupled to vertical vent cap 814 through a B-vent to cap adapter 808, while flex vent liner 810 can be coupled to vent cap 814 through a flex-liner to cap adapter 812.

Having described various embodiments for conversion of direct vent and B-vent fireplace configurations, a method for installation can be further appreciated. With reference to FIG. 9, a method for fireplace conversion 900 comprises preparing for installation by removing the existing shell and components, such as baffle, pan and valve system/burner (910). Once preparation has occurred, then a suitable exhaust adapter is attached to the existing firebox appliance (920). This can entail coupling of adapter plates and flex liners and then collar plates to the existing firebox frame, such as the exhaust adapters illustrated in FIGS. 4A and 4B, installing the integral adapter plate/collar plate as illustrated in FIGS. 4C and 6B, or other of the exhaust adapter configurations illustrated above. Next, the shell body is slid into the sliding collar plate and fastened (930), followed by the dropping of the adjustment legs (940) to level and support the shell body within the existing firebox frame. Once supported, then the replacement firebox can be slid in and otherwise inserted within the shell, and then fastened (950), followed by remaining typical installation of components, such as fans, valve trays, gas lines, fireplace front (such as a low profile trim or other front).

The present invention sets forth a system and method for providing a fireplace conversion that is applicable to various fireplace insert applications. It will be understood that the foregoing description is of exemplary embodiments of the invention, and that the invention is not limited to the specific configurations shown. Various modifications may be made in the design and arrangement of the methods and processes set forth herein without departing from the scope of the invention. These and other changes or modifications are intended to be included within the scope of the present invention. 

1. A converted fireplace system, said fireplace comprising: at least one of an existing firebox frame and exhaust system; a shell comprising a pair of adjusting legs, a pair of framing channels, a body, and a top; the pair of adjusting legs configured to support or level the shell once mounted within the existing firebox; a replacement firebox unit configured to slide within the shell and connect to the framing channels; and an exhaust adapter configured to operatively couple the shell to the existing firebox frame and exhaust system, the exhaust adapter comprising a collar plate to couple to the shell and adapter component for coupling to the firebox frame.
 2. The converted fireplace system according to claim 1, wherein the top of the shell may be integrated with the body of the shell.
 3. The converted fireplace system according to claim 1, wherein the exhaust adapter includes a flex liner in between the collar plate and adapter component.
 4. The converted fireplace system according to claim 3, wherein exhaust adapter is configured to facilitate conversion to a direct vent exhaust system.
 5. The converted fireplace system according to claim 3, wherein exhaust adapter is configured to facilitate conversion to a B-vent exhaust system.
 6. The converted fireplace system according to claim 1, wherein the adapter component comprises at least one of a gasket, adapter plate, and integrated adapter.
 7. A fireplace converter comprising: a shell comprising adjusting legs, framing channels, a body, and a top, wherein the pair of adjusting legs are configured to support or level the shell once it is mounted within an existing firebox; a replacement firebox unit configured to slide within the shell and connect to the framing channels; and an exhaust adapter configured to operatively couple the shell to the existing firebox and an existing exhaust system, wherein the exhaust adapter comprises a collar plate to couple the shell and an adapter component for coupling to the firebox frame.
 8. The fireplace converter according to claim 7, wherein the top of the shell may be integrated with the body of the shell.
 9. The fireplace converter according to claim 7, wherein the exhaust adapter comprises a flex liner in between the collar plate and the adapter component.
 10. The fireplace converter according to claim 7, wherein exhaust adapter is configured to facilitate conversion to a direct vent exhaust system.
 11. The fireplace converter according to claim 7, wherein exhaust adapter is configured to facilitate conversion to a B- vent exhaust system.
 12. A method for converting a fireplace to an different appearance, said method comprising: removing existing shell and components from an existing firebox; attaching an exhaust adapter to the existing firebox; sliding and attaching a shell body to the existing firebox via the exhaust adapter; adjusting legs to support the shell body; and inserting a replacement firebox into the shell body.
 13. The method according to claim 12, said method further comprising attaching framing channels to the shell body to attach the shell body to the existing firebox. 